Breathable And Light Weight Mattress

ABSTRACT

The problems of the prior art are addressed by a novel mattress for an infant play yard, crib, or bed. In one embodiment, a mattress for a play yard, crib, or bed, comprises a plurality of panels. Each panel can comprise a structural layer having a first surface area. The structural layer can comprise a plurality of structural components and a plurality of non-structural components. A supporting surface can be positioned above the structural layer and be in contact with and occupy a second surface area larger than the first surface area. A cushioning layer is supported by the supporting layer. The plurality of panels can be connected to one another to allow for folding and transport of the mattress. In certain embodiments, the structural components comprise ribs and the non-structural components comprise openings between the ribs. The panels may be formed of plastic, metal, wood, or other suitable materials.

The present application claims priority to U.S. Provisional PatentApplication Ser. No. 62/042,872 for “Breathable and Light WeightMattress”, filed Aug. 28, 2014, the disclosure of which is incorporatedherein by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates to a mattress for a play yard, crib, orbed. In particular, the present disclosure relates to a mattress havinga rigid substructure that is breathable, light-weight, and foldable.

BACKGROUND

Play yards are well known in the art. Play yards are structures designedto provide a safe environment for infants and children. Conventionalplay yards are designed to fold into a compact, generally rectangularstructure. When erected, the play yard should be stable, and providesupport to keep the structure standing upright. For maximum convenience,a foldable play yard should be readily collapsible to a storage positionwithout the disassembly of any parts. When stored, the play yard shouldbe easily transportable from one location to another.

Play yards typically include a mattress that may be removed and placedwithin an opened play yard. Play yard mattresses are designed to safelysupport a child or infant placed therein. Play yard mattresses aretypically composed of a plurality of panels made from medium-densityfiberboard (MDF), particle board, or other similar materials. The panelsare connected at hinge points so that they may be folded over oneanother for ease of transportation. The panels may also be folded into asquare tube, or wrapped around a folded play yard. To use, the panelsare unfolded to form a rectangular mattress, which is then placed withinan opened play yard to create a safe surface for play for an infant orchild.

There are a number of issues with conventional play yard mattresses.Mattresses may be heavy or cumbersome, thus affecting the portability ofthe play yard. Infants may also expel bodily fluids onto a mattress,which may collect around the infant and lead to the mattress becomingunsanitary or unsafe. The mattress may retain odors or become stained,which may be minimized, but not eliminated, by the usage of a mattresssheet. Cleaning these mattresses may be cumbersome and sometimesineffective, as bacteria, germs, and other matter may become embeddedwithin the mattress. Further, rebreathing carbon dioxide is acontributing cause of Sudden Infant Death Syndrome (SIDS) andasphyxiation. Conventional crib mattresses, bedding, and materials maylead to rebreathing of carbon dioxide, and therefore may be acontributing environmental cause of SIDS and other ventilation concerns.

Currently, some of these issues are addressed in a variety of ways, withvarying degrees of success. In some cases, the solutions to these issuesare expensive, thereby raising the price of the play yard mattress. Itwould be beneficial if these issues could be addressed in a safe,convenient and cost effective manner.

SUMMARY

The problems of the prior art are addressed by a novel panel for amattress. The panel may be used in mattresses for a play yard, crib,bed, or other furniture designed to accommodate an infant or child. Inone embodiment, the problems of excess weight and lack of breathabilityare solved by a play yard mattress composed of a plurality of panelshaving structural components and non-structural components. Theplurality of panels are connected to one another to allow for folding,thus creating a foldable play yard mattress. The combination providessufficient structural support for the panel, yet results in alight-weight structure. Further, the non-structural components mayincrease breathability of both the panel and mattress.

An object of the invention is to provide a light weight and breathablemattress for use by an infant or child. To achieve this object,embodiments of the disclosure may comprise a mattress having a rigidsubstructure with perforations, covered by a soft fabric.

In some embodiments, the structural and non-structural components maycomprise a design, which further may comprise a repeated pattern. Thedesign may be any design, such as hexagons, triangles, circles, squares,cross-hatch, or herringbone patterns. The structural components maycomprise ribs surrounding the non-structural components, and thenon-structural components may be open spaces between the ribs.Alternately, the non-structural components may comprise areas of thepanel having a thinner wall thickness than the structural components.

In some embodiments, the panels are formed of molded plastic. The panelsmay be formed using suitable plastic molding techniques, which mayinclude gas assist injection molding, blow molding, and rotationalmolding. In other embodiments, the panels may be formed of metal, suchas machined aluminum, or even wood.

In some embodiments, the panels are connected to one another using ahinge, such as a living hinge or metal hinge. The panels may also becovered in fabric and soft material, such as batting, foam, or rubber,thus making the contact surface of the panel soft and walkable. In afurther embodiment, the fabric and soft material may be replaced in theevent of stains or retained odors. The plurality of panels may comprisefour, five, or any number of panels.

In some embodiments, each panel may be formed from an upper and a lowerpanel, each having an edge, structural components, and non-structuralcomponents. The panels are stacked on top of one another such that theedges of each panel are in contact, thus forming an interior spacebetween the panels. In other embodiments, the structural components ofthe upper and lower panels are in contact. The panels may be connectedusing heat welding, screws, snaps, or a living hinge.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present disclosure, reference is madeto the accompanying drawings, which are incorporated herein by referenceand in which:

FIGS. 1A-D are top views of several embodiments of panels according toembodiments of the disclosure,

FIG. 2A is a cross-sectional view along the line A-A′ in FIG. 1A, andFIG. 2B is a cross-sectional view along the line B-B′ in FIG. 1A;

FIG. 3 is a cross-sectional view of a compound panel formed from anupper panel and a lower panel according to an embodiment of thedisclosure;

FIGS. 4A-B are cross-sectional views of embodiments of panels accordingto the disclosure comprising ribs having interior spaces;

FIGS. 5A-D are top, bottom, perspective, and zoomed perspective views ofa panel comprising a supporting surface for accommodating a foam backingor other material according to the disclosure;

FIGS. 6A-D are top, bottom, perspective, and zoomed perspective views ofanother embodiment of a panel comprising another embodiment of asupporting surface for accommodating a foam backing or other materialaccording to the disclosure;

FIGS. 7A-B are top perspective and bottom perspective views,respectively, of the panel of FIGS. 6A-D and further comprising a foambacking adhered to the supporting surface;

FIG. 8A is a cross sectional view along line C-C′ of the panel of theembodiment of the panel of FIG. 7A, and FIGS. 8B-E are cross-sectionalviews of additional embodiments of panels comprising embodiments ofsupporting surfaces according to the disclosure;

FIG. 9 is a top view of a plurality of panels, such as the panel of FIG.1A, hingedly attached to form the rigid substructure of a play yardmattress according to one embodiment of the disclosure;

FIGS. 10A-B are perspective views of the top and bottom, respectively,of an unfolded or opened play yard mattress comprising multiple panelsof FIG. 8B, and FIGS. 10C-D are perspective and top views of the playyard mattress of FIGS. 10A-B in a folded or closed configuration; and

FIG. 11 is a perspective view of a play yard illustrating two positionsfor placement of a mattress.

DETAILED DESCRIPTION

FIG. 1 shows a front view of a single panel 100 of a mattress for a playyard, crib, or bed according to one embodiment of the instantdisclosure. In this embodiment, the panel 100 is formed from moldedplastic; however, a variety of materials may be used. For example,panels within the scope of the disclosure may be formed from plastic,metal, cardboard, rubber, wood, and the like. The panels may be molded,machined, or cast. As will be discussed in further detail below, thepanel 100 may be combined with several similar panels according to thedisclosure in order to form a mattress. In particular, the panel 100serves as a rigid, yet light-weight substructure for the mattress, thusproviding stability for the mattress. However, the panel 100 also allowsfor ventilation and transmission of fluids and gases, and certainembodiments further comprise soft surfaces for placing an infant orchild thereon.

The panel 100 has an edge 102 forming its perimeter. The edge 102 maycomprise the same material as the panel, or alternately may be composedof a different material. In certain embodiments, the edge 102 may beomitted. The panel 100 further comprises a plurality of structuralcomponents 106 and a plurality of non-structural components 108. Thestructural components 106 are configured to provide support, strength,and stability for the panel 100, whereas the non-structural components108 are configured to reduce the weight of the panel 100. Further, asshown in this embodiment, the structural components 106 andnon-structural components 108 may be arranged to comprise a pattern 104.

As shown in this embodiment, the pattern 104 can comprise a repeatedhexagonal design. However, the hexagonal design is only exemplary, andit should be understood that other patterns or shapes may be used, suchas triangles, circles, squares, cross-hatch, or herring-bone patterns.The pattern 104 may be repeating or non-repeating. Further, the pattern104 may comprise any shape, design, or figure, and not just geometricshapes. In certain embodiments, the pattern 104 may comprise multipleshapes or patterns. The use of a pattern 104 is helpful in providing adesign for the structural components 106; however, certain embodimentsmay also lack the use of a pattern 104 according to the disclosure.

The structural components 106 can comprise ribs surrounding the edges ofeach shape in the pattern 104, which as shown in this embodimentcomprises a hexagonal design. However, in certain embodiments thestructural components 106 can comprise other various internal featuresof the panel 100. In particular, the structural components 106 may beconfigured to provide support, strength, or stability for the panel 100.Preferably, the structural components 106 should comprise non-deformableor non-elastomeric materials, and thus be able to rely on their owntensile properties for support, as opposed to requiring anothercomponent or set of components to provide structural support for thepanel 100. The structural components 106 should also preferably be ableto maintain these properties when the weight of an infant or child isplaced on the panel 100, such that the panel 100 may be used as acomponent of or as a mattress for a play yard, crib, or other enclosure.

As shown in this embodiment, the non-structural components 108 cancomprise the width or distance between the structural components 106.For example, the non-structural components 108 can comprise a pluralityof openings or cutouts in the panel, such as the hollow or open centersof each shape in the pattern 104. Accordingly, the non-structuralcomponents 108 create a channel between the top and bottom of the panel100. The non-structural components 108 provide the benefits of reducingthe weight of the panel 100, reducing material usage, and also allowingventilation and drainage of gas and fluid when the panel 100 is used aspart of a mattress for a play yard, crib, or other enclosure.Preferably, the non-structural components 108 are configured to providethese benefits without affecting the structural integrity of the panel100.

In certain embodiments, the non-structural components 108 may simply bethinner portions of the panel 100, rather than hollow segments,openings, a width, or volume between the structural components 106. Forexample, the panel may be formed such that the wall thickness of thenon-structural components is thinner than that of the structuralcomponents. Alternately, the pattern may comprise various combinationsof both open and thinned non-structural components 108. Certainembodiments can taper between the structural and non-structuralcomponents. Various configurations and combinations of structuralcomponents and non-structural components are within the scope of thepresent disclosure.

As previously noted, panels 100 according to the disclosure may comprisea variety of materials. For example, suitable plastic materials includepolypropylene, reinforced polypropylene, nylon, reinforced nylon,polyvinyl chloride, plastic blends (including blends comprising glassfibers and carbon fibers), and the like. Panels formed of metal maycomprise aluminum, titanium, and the like. Still further embodiments mayemploy wood, cardboard, and other materials. Various embodiments andmaterial usage are considered to be within the scope of the disclosure.

To achieve an optimal balance between weight and stability, a ratiobetween the panel surface area comprising the structural components 106and the panel surface area comprising non-structural components 108 maybe varied. Increasing the surface area of the panel occupied by thestructural components 106 will increase stability of the panel 100, atthe expense of increased weight. In contrast, increasing the surfacearea of panel occupied by the non-structural components 108 willdecrease weight, yet also decrease stability. For example, one may varyboth the dimensions of each shape in the pattern 104, the size of theribs surrounding or forming the shape, and the spacing between the ribsor size of the openings or non-structural components 108. Increasing theaverage size of the shape in the pattern 104 leads to a larger opensurface area, thus decreasing the overall weight of the panel. However,this also results in decreased stability and increased flexion, whichcan be undesirable when the panel is used to support an infant or child.These effects may be countered by increasing the width of the ribsforming each shape, which reduces the cumulative open surface area ofthe panel, thus increasing stability. In certain embodiments, theseeffects may also be moderated by choosing lighter or stronger materialsfor the structural components 106.

FIGS. 1B-1C illustrate further variations of panels 120, 140 accordingto embodiments of the disclosure. Similar to the panel 100, the panels120, 140 comprise edges 122, 142; patterns 124, 144; structuralcomponents 126, 146; and non-structural components 128, 148,respectively. The panel 120 in FIG. 1B features a pattern 124 havingrepeated hexagons of a larger width than those in the panel 100 of FIG.1A. As discussed above, this property leads to a larger percentage ofthe surface area of the panel 120 devoted to non-structural components128. The increased open surface area of the panel results in a panelhaving both decreased weight and decreased stability. If the resultingdecrease in stability is unacceptable, this effect may be compensated byincreasing the percentage of the panel 120 devoted to structuralcomponents 126 by increasing the size of the ribs forming or surroundingeach shape in the pattern 124, 144, by using a stronger material for thestructural components 126, 146, or a combination of approaches.

Similarly, the panel 140 in FIG. 1C features a pattern 144 havingsmaller hexagons than the panel 100 of FIG. 1A, thus decreasing thesurface area devoted to non-structural components 148 and increasing thesurface area devoted to structural components 146. This increases bothstability and weight. If the increase in weight is unacceptable, thiseffect may be compensated by decreasing the width of the ribssurrounding and forming each hexagon, by using a weaker material, or byusing a combination of approaches. Accordingly, the ratio betweenstructural and non-structural components may be varied until anacceptable balance between weight and stability is achieved. In certainembodiments, the percentage of surface area of the panel devoted to theopenings or non-structural components 128 is greater than that devotedto the structural components 126. This feature is particularly useful toaid in both ventilation of air and drainage of liquids.

In these embodiments, the structural components 106, 126, 146 of panels100, 120, 140 are approximately 8-10 mm tall. Each panel can beapproximately 670 mm (26.4″) in length long and 240 mm (9.44″) in width.These particular dimensions are useful for connecting multiple panelstogether to form a mattress. However, in certain embodiments, variousother dimensions and shapes may be used to accommodate a variety of playyards or other structures. For example, in certain embodiments a panelaccording to the disclosure may be circular, elliptical, triangular,rectangular, star-shaped, heart-shaped, and the like. In certainembodiments, the width of the structural components can be 1.8-2.0 mmand the width of the non-structural components can be about 25 mm.Further, in certain embodiments, panels can have a width that is greaterthan or equal to its length.

The panel 100 and structural components 106 may be formed using avariety of methods. For example, in certain embodiments a panel cancomprise plastic, which may be formed using gas assist injectionmolding. In this case, the interior of the ribs may be cleared out inthe gassed area, leaving an interior space. Gas assist injection moldingmay also be used to finely tune the wall thickness of the panel and ribsize. Other suitable methods for molding may be used, such as blowmolding and rotational molding. As previously noted, suitable plasticmaterials for molding include polyethylene, polypropylene,polycarbonate, nylon, and reinforced composites of these materials, forexample.

As previously noted, in certain embodiments, panels according to thedisclosure may also comprise other materials, such as metal, wood, andthe like. FIG. 1D illustrates another embodiment of a panel 160according to an embodiment of the disclosure. In this embodiment, thepanel 160 comprises an aluminum sheet comprising an edge 162, a pattern104, structural components 166, and non-structural components 168. Asshown in this embodiment, the non-structural components 168 can comprisethe perforations or holes formed in the aluminum, and the structuralcomponents 166 comprise the portions of the panel 160 which have notbeen perforated. In various embodiments, the size, number, arrangement,and shape of the perforations can be varied to achieve a desired ratioof stability and weight. In certain embodiments, aluminum may bepreferred over plastic materials as it is a light weight and strongmaterial. However, in certain embodiments plastic may be preferred, asit may take advantage of specialized molding techniques which may beused to include other features, as will be discussed in additionaldetail below.

FIG. 2A is a cross-sectional view along the line A-A′ of FIG. 1A andillustrates the structure of the structural components 106 andnon-structural components 108 in the panel 100. As previously noted, inthis embodiment, the structural components 106 comprise ribs surroundingthe edges of the non-structural components 108. As shown in thisembodiment, the ribs can have a thickness (i.e., the height between thetop and bottom of the panel 100) that tapers from a maximum thickness210 to a minimum thickness 205.

FIG. 2B illustrates a cross-sectional view along lines B-B′ of the panel160 of FIG. 1D. As previously noted with respect to FIG. 1D, the panel160 lacks ribs and a raised edge. In this embodiment, the structuralcomponents 166 comprise the wall thickness 215 (i.e., height) of thepanel 160 between the non-structural components 168. For example, thenon-structural components 168 of FIG. 2B may simply be openings,cutouts, perforations, or other features punched or machined into thepanel 160, thus leaving the wall thickness of the panel 160 remaining asthe structural components 106.

FIG. 3 illustrates another embodiment of a panel 300 according to thedisclosure. As shown in this embodiment, the panel 300 can comprisemultiple panels, such as an upper panel 310 and a lower panel 320, whichmay be stacked together or otherwise combined to form a combined panel300. Similar to the panel 100, the panels 310, 320 further comprisestructural components 306 and non-structural components 308. The panelsare stacked such that an upper panel edge 302 on the upper panel 310 isin contact with a lower panel edge 303 on the lower panel 320, thusforming an interior space 330 between the two panels 310, 320. Further,as shown in this embodiment, the combination of the non-structuralcomponents 308 and interior space 330 creates a channel providing fluidcommunication between the top and bottom of the panel 300.

In certain embodiments, the structural components 306 of the upper andlower panels 310, 320 may first be aligned prior to stacking. In certainembodiments, the edges of the panels 310, 320 may be connected by aliving hinge, welded, heat-sealed, screwed, or snapped together. In thisway, the combined panel 300 has a thickness 340 (i.e., height) that islarger than the thickness of a single panel, yet the combined panel 300can still be strong, breathable, and light weight. In certainembodiments, the ribs or structural components 306 of the two panels mayalso be connected. In other embodiments, the panels 310, 320 may bereleasably attached for ease of assembly and disassembly.

In certain embodiments, structural components may further comprise ahollow or open interior. FIGS. 4A-B illustrate cross-sectional views ofembodiments of panels 400, 405 according to the disclosure comprisingstructural components 406 and non-structural components 408, of whichthe structural components 406 further comprise interior spaces 412. FIG.4A illustrates the panel 400 as comprising two sections 401, 402 thatcombine together to form the structural components 406 (i.e., as shownin this embodiment, ribs). Further, in this embodiment, the combinationof the two sections 401, 402 leaves an interior space 412 within the ribitself, thus resulting in a rib that is thicker, yet having reducedweight due to an air pocket formed within the interior space 412.

In certain embodiments, an interior space 412 may be formed instructural components 406 through means other than stacking two separatesections. FIG. 4B illustrates a cross-sectional view of the panel 405that has been formed using a gas-assist or blow molding technique.Accordingly, in this embodiment, the interior space 412 has been formeddirectly within the structural component 406 itself during fabrication,as opposed to by joining two separate sections together. In certainembodiments, this may be preferable as it helps to ensure integrity ofthe structural component 406 and thus prevent breaching of the interiorspace 412.

Further, the use of an interior space 412 may be particularlyadvantageous in embodiments of panels that require a wider rib, such asfor attachment to another surface or foam backing, for example.Accordingly, in this embodiment, the structural components 406 canprovide a contact surface area which may be used for attachment orsupport of a foam panel or other soft material.

As previously noted, panels according to the disclosure may serve as amattress or a component of a mattress for a play yard, crib, or otherenclosure. The mattress should preferably provide a soft and walkablesurface for a caregiver to place a child or infant. In certainembodiments, panels according to embodiments of the disclosure may becovered in covered in fabric and soft material, thus making the contactsurface of the panel soft and walkable. The soft material may comprisefoam, breathable foam, three-dimensional mesh, spacer mesh, batting,rubber, or any other suitable material. A combination of soft materialsmay be used, e.g., a foam backing and a sheet or mattress cover.Further, the fabric and soft material may be removable such that if thematerials begin to retain odor, or become stained, torn, or frayed, theymay simply be removed for washing or replacement. However, in otherembodiments, the fabric and soft material may not be replaceable tominimize the number of seams and/or failure points for the fabric, anddepending on other considerations regarding longevity and intended use.

FIGS. 5A-D illustrate another embodiment of a panel 500 according to thedisclosure. Similar to previous embodiments of panels disclosed herein,as shown in this embodiment, the panel 500 comprises an edge 502, apattern 504, structural components 506, and non-structural components508. Further, the panel 500 comprises a supporting surface 516positioned above the structural components 506. The supporting surface516 comprises a planar surface above the structural components 506 thatincreases the available surface area of the panel to support anadditional cushioning layer, such as a soft material configured tosupport an infant or child. Suitable soft materials can comprise foam,mesh, padding, and the like. Additionally, as shown in this embodiment,the supporting surface 516 can comprise openings 518 or perforationspositioned above the non-structural components 508, thus creating achannel between the top and bottom of the panel 500 and maintainingbreathability of the panel 500.

In this embodiment, the panel 500 comprises injection molded plastic.Accordingly, the panel 500, structural components 506, and supportingsurfaces 516 may be formed together as a single plastic component.However, in certain embodiments, supporting surfaces 516 according tothe disclosure may also be added later as a separate component from thestructural components 506. For example, the supporting surface 516 maycomprise a sheet of plastic or other material that is adhered to thestructural components 506; thus, the openings 518 in the supportingsurface 516 may comprise holes, openings, or perforations punched intothe supporting surface 516. Preferably, the openings 518 should bepositioned over the non-structural components 508 to create a channelbetween the top and bottom of the panel 500, thus ensuring breathabilityand the ability to transfer gas, liquid, air, and other materialsthrough the panel 500.

A supporting surface 516 provides a variety of benefits for a panelaccording to the disclosure. For example, as shown in this embodiment,the supporting surface 516 provides additional stability for the panel500 by preventing twisting or torsion of the structural components 506.Additionally, the supporting surface 516 provides additional strength tothe panel 500, thus allowing for the use of thinner structuralcomponents 506 or structural components 506 comprising materials thatwould otherwise not be practical or provide sufficient strength.Accordingly, while the first contact surface area of the structuralcomponents 506 may be insufficient to adhere to a cushioning layer, theprovision of a second, larger, contact surface area by the use of asupporting layer or supporting surface 516 helps to attach thestructural components 508 to a cushioning layer or other soft materialwithout increasing the size of the structural components 506, thushelping to keep the panel light weight.

FIGS. 6A-D illustrate another embodiment of a panel 600 comprising anedge 602, structural components 606, and non-structural components 608,and a supporting surface 616 according to the disclosure. In contrast tothe supporting surface 516 of the panel 500, as shown in thisembodiment, the supporting surface 616 can comprise openings 618 havingsubstantially the same shape (i.e., hexagonal) as the non-structuralcomponents 608. As shown in this embodiment, the feature may help tofacilitate fabrication of the panel during fabrication, such as byinjection molding or other plastic fabrication techniques. Further,having the openings substantially conform to the shape of the pattern604 helps to maximize air flow and ventilation by maximizing the amountof open area between the top and bottom of the panel 600.

While in these embodiments, the supporting surfaces 516, 616 comprisefeatures that are positioned above the structural components 506, 606,respectively, in certain embodiments supporting surfaces according tothe disclosure may extend outwardly from structural components accordingto the disclosure. For example, in certain embodiments, a supportingsurface may comprise protrusions that extend longitudinally from astructural component or rib according to the disclosures. Theprotrusions may have a surface along the same plane as the top of thestructural components. Accordingly, the protrusions would similarlyprovide a larger surface area for attachment of an additional componentas compared to only the structural components. Various embodiments andequivalents are considered to be within the scope of the disclosure.

FIGS. 7A-B illustrate the panel 600 of FIGS. 6A-D, and furthercomprising a cushioning layer, such as a foam backing 650 adhered to thesupporting surface 616. As previously noted, the supporting surface 616facilitates attachment of the foam backing 650 by increasing theavailable surface area on the top of the panel 600 (i.e., by reducingthe amount of surface area on the top of the panel occupied by thenon-structural components) available for attachment to the panel. Thefoam backing 650 allows for the panel 600 to be used as a soft surfacefor a caregiver to safely place a child or infant thereon. Ideally, thefoam backing 650 should be chosen or configured such that the infant orchild does not sufficiently come into contact with the structuralcomponents 608. Though in this embodiment the foam backing 650 is onlyattached to one side of the panel 600, in other embodiments foam backingor other soft material may be attached on both sides. Further, due tothe non-structural components 608, the panel 600 will be breathable,promoting air flow and allowing for liquids placed on the foam backing650 to drain. Preferably, the foam backing 650 will comprise a materialthat is gas and liquid permeable and washable. Examples of suitablematerials for use as a foam backing 650 can comprise nylon foam,closed-cell or open-cell foam, EVA foam, 3D mesh, spacer mesh,polyurethane foam, and the like.

As shown in this embodiment, the foam backing 650 may be attached to thepanel 600 and supporting surface 616 using glue, Velcro, byover-molding, or any other fastening means. However, in certainembodiments, the foam backing 650 may not be securely attached to thepanel 600, and instead may simply be positioned over and supported by,or otherwise in contact with the panel 600 and/or supporting surfaces616.

As shown in this embodiment, the foam backing 650 can further compriseopenings 652 positioned over the openings 618 of the supporting surface616, which in turn are positioned over the non-structural components608, thus forming a channel between the upper and lower sides of thepanel 600. As previously noted, this maintains the breathability of thepanel, allowing for both air flow and drainage. As shown in thisembodiment, the openings 652 match the size of the supporting surface616, thus maximizing breathability. However, in certain embodiments, theopenings 652 can be sized smaller or larger than the supporting surface616. For example, in certain embodiments the soft material may be softenough such that a child or infant placed thereon would contact thestructural components 506. In these embodiments, it may be preferable toreduce the size of the openings 652 to slightly overlap the supportingsurface 616 and structural components 606.

FIG. 8A illustrates a cross-sectional view of the panel 600 along lineC-C′ in FIG. 7A. As shown in this embodiment, the supporting layer orsurface 616 can be molded together as a component of the structuralcomponents 606. The use of the supporting surface 616 allows for thestructural components 606 to be thinner, thus further decreasing theweight of the panel 600. Accordingly, the supporting surface 616 can bewider than the structural components 606, thus presenting a largercontact surface area for supporting or attaching the foam backing 650.In this embodiment, the width of the structural components 606 is 1.8-2mm, the width of the non-structural components 608 is 25.4 mm, and thewidth of the supporting surface 616 is 5-6 mm. The height or thicknessof the structural components 606 can be 10 mm, or even less. Forexample, if the panel 600 comprises reinforced polypropylene, the heightof the rib can be 8 mm.

As shown in this embodiment, the combination of the non-structuralcomponents 608, openings 618, and openings 652 create a channel betweenthe top and bottom of the panel 600, allowing fluid communication forgas and liquid. FIG. 8B illustrates a cross-sectional view of the panel600 of FIG. 7A with the foam backing 650, and further comprising anouter layer 660. In the embodiment shown, the outer layer 660 completelysurrounds both the panel 600 and foam backing 650. In certainembodiments, the outer layer 660 may comprise a thin mesh material.

The outer layer 660 serves as an additional layer for providing a softsurface for placing an infant or child. Additionally, the outer layer660 can also prevent foreign objects or other materials from occupyingor blocking the channel defined by the non-structural components 608,openings 618, and openings 652. Further, in certain embodiments, theouter layer 660 may be removable. In this way, the outer layer 660 maybe removed to allow for cleaning or replacement of either the outerlayer 660 or the panel 600. Further, in embodiments where the outerlayer 660 comprises mesh or other breathable materials, the ventilationof the channel defined by the non-structural components 608, openings618, and openings 652 will not be severely impacted.

FIG. 8C illustrates a cross-sectional view of the panel 600 comprisinganother embodiment of a cushioning layer or foam backing 670 accordingto the disclosure. As shown in this embodiment, the foam backing 670 mayinstead comprise a single continuous planar sheet of a soft material,and thus lack openings 652, as compared to the foam backing 650 of FIGS.8A-B. In these embodiments, it may be preferable to use materials havingincreased breathability, thus continuing to allow the transfer of airand fluids between the upper and lower portions of the panel 600 throughthe non-structural components 608 and openings 618 of the supportingsurface 616.

FIG. 8D illustrates a cross-sectional view of another embodiment of apanel 700 comprising structural components 706 and non-structuralcomponents 708, the structural components 706 further comprising asupporting surface 716 for a foam backing 760 that is thinner than thestructural components 706. In particular, as shown in this embodiment,the supporting surface 716 comprises a protrusion extending from thestructural components 706. Further, in this embodiment, the foam backing760 further comprises a groove 718 that securely fits over thesupporting surface 716. In certain embodiments, this feature helps tokeep the foam backing 760 firmly attached to the panel 700. However,compared to the panel 600 of FIGS. 8A-C, the panel 700 requiresstructural components 706 that are relatively wider, potentiallyincreasing the weight of the panel. In certain embodiments, thestructural components 706 may further comprise interior spaces (e.g.,the interior spaces 412 of FIGS. 4A-B) to decrease the weight of thepanel 700 accordingly.

FIG. 8E illustrates a cross-sectional view of another embodiment of apanel 720 comprising structural components 726 and non-structuralcomponents 728, the structural components 726 further comprising asupporting surface 736 for a foam backing 770. In this embodiment, thesupporting surface 736 comprises a groove sized to accommodate aprotrusion 738 extending from the foam backing 770. For example, thefoam backing 770 may be prefabricated and then pressed onto thesupporting surface 736. In other embodiments, the foam backing 770 mayinstead comprise rubber or another moldable material, which may beover-molded directly into the supporting surface 736. Variousembodiments are considered to be within the scope of the disclosure.

It should be noted that the individual features described herein may becombined with one another to present various embodiments of a mattress.For example, a mattress according to the instant disclosure may comprisetwo panels stacked on one another, and also feature ribs and asupporting surface to allow placement of a foam backing or other softmaterial. In certain embodiments, foam backings or other soft materialshaving openings or no openings may be adhered to a variety of supportingsurfaces, or directly to a structural component or rib. Each of theabove described features may be combined with one another to formvarious panels and mattress according to the disclosure.

FIG. 9 is a top view of a mattress 800 for a play yard, crib, or bedaccording to an embodiment of the instant disclosure. The mattress 800can comprise four panels; in this embodiment, each panel is the panel100 as shown in FIG. 1A. However, mattresses according to the disclosuremay comprise various panels according to the disclosure, includingdifferent embodiments or combinations of panels. The panels areseparated by a gap 810 and are connected by an attachment mechanism 820which allows the panels to pivot with respect to one another.

The attachment mechanism 820 can comprise a hinge, allowing the panels100 to pivot with respect to one another such that the mattress 800 maybe folded. However, the attachment mechanism may be any means ofattaching panels to one another, such as a living hinge, straps, snaps,movable joint, or other mechanism. The gap 810 and attachment mechanism820 allow the panels to be folded against each other, or to form asquare tube. This aids portability, as the panels may thus be wrappedaround a folded play yard and used as a box. Alternately, the panels maybe stacked on one another and stored with or adjacent to a folded playyard.

FIGS. 10A-B illustrate another embodiment of a mattress 900 according tothe disclosure. Similar to the mattress 800, the mattress 900 comprisesfour panels. In this embodiment, the panels comprise the panel 600 ofFIG. 7A, and accordingly comprise a foam backing 650 secured tosupporting surfaces 616 and surrounded by an outer layer 660. The panels600 serve as a rigid substructure for the foam backing 650 and outerlayer 660, thus resulting in a light weight, breathable, yet soft,mattress 900. As previously noted, the foam backing 650 can comprisebreathable foam, 3D mesh, spacer mesh, and the like to allow air flowand liquid drainage through the non-structural components 608. Finally,the outer layer 660 surrounds the panel 600 and foam backing 650,providing a soft surface for placing an infant or child thereon.

FIGS. 10C-D illustrate the mattress 900 when folded. As the mattress 900comprises four panels 600, it may be folded along the gaps 810 into arectangular structure, creating a volume 910 for receiving a collapsedplay yard or other objects. Though the mattresses 800, 900 in thisembodiment comprises only four panels, more or fewer panels may be used.For example, if the average panel width is shorter, more panels may berequired to create a full-length mattress according to the disclosure.In some embodiments, a play yard mattress uses five panels. Four- andfive-panel configurations are beneficial because they allow for easyfolding into a box-like structure to contain the folded play yard.However, in certain embodiments, panels may simple be folded over ontoone another into order to form a compact structure for storage ortravel. However, in some embodiments the mattress may comprise only asingle panel.

In some embodiments, mattresses according to the disclosure may bedisassembled into individual panels for ease of storage, or for panelreplacement. Alternately, the panels may be permanently attached.

As described above for panels according to the instant disclosure, themattresses 800, 900 may be covered in fabric and soft material, thusmaking the contact surface soft and walkable. Further, the hollow oropen surface area of the panels (e.g., the channel created by thenon-structural components, openings in the supporting surface, andopening in the foam backing) leads to the unique property of increasingbreathability for the mattresses 800, 900 thus providing for an airlayer beneath the fabric and soft batting. Breathability is desired asit provides more air to an infant or child within the play yard, andalso helps to prevent mold, bacteria, or odors from settling within themattresses 800, 900. Further, the combination of layers, i.e., a meshouter layer 660, foam backing layer (e.g., foam backing layer 650), anda rigid sublayer or structural layer (e.g., the panel 600), results in amattress 800, 900 this is also sturdy and light weight.

In use, the mattresses 800, 900 may be unfolded flat and then placedwithin a play yard. As illustrated by FIG. 11, a mattress according tothe present disclosure may be used in various locations of a play yard1000. For example, infants who do not yet have the ability to pullthemselves up or to stand may sleep comfortably on the mattress placedin the bassinet position 1010. However, older children with increasedmobility will be safely contained if the mattress is placed in the floorposition 1020 instead. Alternately, the mattresses 800, 900 may even beused without a play yard to simply provide a clean and soft surface toplace an infant or child.

When not in use, mattresses according to embodiments of the disclosuremay be folded and wrapped around a folded play yard, thus forming aconvenient package for travel.

It should be noted that embodiments of panels according to the instantdisclosure may comprise any form of structural and non-structuralcomponents in a panel. As discussed above, other shapes in a pattern maybe used. Multiple patterns and designs may be used in a single panel.The panels may vary in their dimensions. The ribs or structuralcomponents may comprise a variety of shapes and configurations.Mattresses may be formed from a single panel or from multiple panels.The panels may be connected by hinges or other forms of attachmentmechanisms.

Embodiments of the disclosure may be used in any kind of mattress. Forexample, embodiments of panels according to the disclosure may be usedas a surface for resting by adults, such as for camping. Further, whilevarious layers or components of panels are described hereinabove, theselayers may be omitted or used in combination with other layers orfeatures to form embodiments of panels according to the disclosure.Moreover, layers according to the disclosure do not need to be formed ofdifferent materials or manufactured separately; for example, asupporting layer or surface and a structural component according to thedisclosure may comprise a single piece of molded plastic, metal, orother material.

The present disclosure is not to be limited in scope by the specificembodiments described herein. Indeed, other various embodiments of andmodifications to the present disclosure, in addition to those describedherein, will be apparent to those of ordinary skill in the art from theforegoing description and accompanying drawings. Thus, such otherembodiments and modifications are intended to fall within the scope ofthe present disclosure. Furthermore, although the present disclosure hasbeen described herein in the context of a particular implementation in aparticular environment for a particular purpose, those of ordinary skillin the art will recognize that its usefulness is not limited thereto andthat the present disclosure may be beneficially implemented in anynumber of environments for any number of purposes. Accordingly, theclaims set forth below should be construed in view of the full breadthand spirit of the present disclosure as described herein.

What is claimed is:
 1. A mattress for a play yard, crib, or bed,comprising: a plurality of panels, wherein each panel of the pluralityof panels comprises: a structural layer comprising a plurality ofstructural components and a plurality of non-structural components, eachof the plurality of structural components and plurality ofnon-structural components having a width; a supporting surfacepositioned above the structural layer, the supporting surface in contactwith the plurality of structural components and further comprisingopenings having a width smaller than the width of the non-structuralcomponents, the openings positioned over and in communication with thenon-structural components; and a cushioning layer supported by thesupporting surface; wherein the plurality of panels are connected to oneanother to allow for folding of the mattress.
 2. The mattress of claim1, wherein the plurality of structural components comprise ribs, and theplurality of non-structural components comprise open spaces between theribs.
 3. The mattress of claim 1, wherein the plurality of structuralcomponents and the supporting surface are adhered together.
 4. Themattress of claim 1, wherein the openings are in communication with theplurality of non-structural components of the structural layer.
 5. Themattress of claim 4, wherein the cushioning layer further comprises aplurality of openings, each of the plurality of openings incommunication with one of the openings in the supporting surface.
 6. Themattress of claim 1, wherein the supporting surface comprises a planarsurface.
 7. The mattress of claim 1, wherein the cushioning layercomprises a foam material.
 8. The mattress of claim 1, furthercomprising an outer layer enveloping each panel.
 9. The mattress ofclaim 8, wherein the outer layer comprises mesh.
 10. The mattress ofclaim 1, wherein the structural layer, supporting surface, andcushioning layer each have a length and width that is substantially thesame.
 11. The mattress of claim 1, wherein the plurality of structuralcomponents comprise a wall thickness of the panel surrounding theplurality of non-structural components.
 12. A mattress for a play yard,crib, or bed, comprising: a plurality of panels, wherein each panel ofthe plurality of panels comprises: a rigid layer having a first contactsurface area, the rigid layer comprising a plurality of ribs andopenings between the ribs; a cushioning layer supported by the rigidlayer, the cushioning layer configured to prevent an infant or childfrom substantially contacting the rigid layer; wherein the plurality ofpanels are hingedly connected to one another to allow for folding of themattress.
 13. The mattress of claim 12, wherein the cushioning layerfurther comprises openings in communication with the openings betweenthe plurality of ribs.
 14. The mattress of claim 12, wherein theplurality of ribs further comprises a design.
 15. The mattress of claim14, wherein the design is selected from the group consisting ofhexagons, triangles, circles, squares, cross-hatch, and herringbonepatterns.
 16. The mattress of claim 14, wherein the design is a repeateddesign.
 17. The mattress of claim 12, further comprising a supportinglayer positioned above the ribs, the supporting layer in contact withthe ribs and having a second contact surface area larger than the firstcontact surface area; wherein the supporting layer supports thecushioning layer.
 18. The mattress of claim 12, further comprising anopen space in the interior at least one of the plurality of ribs. 19.The mattress of claim 12, wherein the plurality of structural componentscomprise a material selected from the group consisting of machinedaluminum and molded plastic.
 20. A panel for a play yard, crib, or bed,comprising: a structural layer having a first contact surface area, thestructural layer comprising a plurality of structural components and aplurality of openings; a supporting layer positioned above thestructural layer, the supporting layer in contact with the first contactsurface area and occupying a second contact surface area larger than thefirst contact surface area, the supporting layer further comprisingopenings in fluid communication with the openings in the structurallayer; a cushioning layer supported by the supporting layer, thecushioning layer in contact with the second contact surface area andhaving openings in fluid communication with the openings in thesupporting layer; and a mesh layer surrounding the structural layer,supporting layer, and cushioning layer; wherein the structural layer,supporting layer, and mesh layer each have a length and width that issubstantially the same.